Abstract
The cutting power consumption of milling has direct influence on the economic benefits of manufacturing particle boards. The influence of the milling parameters on the cutting power were investigated in this study. Experiments and data analyses were conducted based on the response surface methodology. The results show that the input parameters had significant effects on the cutting power. The high rake angle reduced the cutting force. Thus, the cutting power decreased with the increase in the rake angle and the cutting energy consumption was also reduced. The cutting power increased with the rotation speed of the main shaft and the depth of milling induced the impact resistance between the milling tool and particle board and the material removal rate. The p-values of the created models and input parameters were less than 0.05, which meant they were significant for cutting power and power efficiency. The depth of milling was the most important factor, followed by the rotation speed of the main shaft and then the rake angle. Due to the high values of R2 of 0.9926 and 0.9946, the quadratic models were chosen for creating the relationship between the input parameters and response parameters. The predicted values of cutting power and power efficiency were close to the actual values, which meant the models could perform good predictions. To minimize the cutting power and maximize the power efficiency for the particle board, the optimized parameters obtained via the response surface methodology were 2°, 6991.7 rpm, 1.36 mm for rake angle, rotation speed of the main shaft and depth of milling, respectively. The model further predicted that the optimized parameters combination would achieve cutting power and power efficiency values of 52.4 W and 11.9%, respectively, with the desirability of 0.732. In this study, the influence of the input parameters on the cutting power and power efficiency are revealed and the created models were useful for selecting the milling parameters for particle boards, to reduce the cutting power.
Highlights
Introduction iationsUnder the environmental protection goal of carbon neutrality and carbon peak, sustainable manufacturing has become the new development direction of the manufacturing industry
From the plot of interaction impact trend, it is easy to see that a higher cutting power was required when milling with the combination of a higher depth of milling, a higher rotation speed of the main shaft and a lower rake angle
For the response surface methodology (RSM) quadratic models for Pc and η, the F-value analysis revealed the depth of milling as the most important factor, followed by the rotation speed of the main shaft and the rake angle
Summary
Samples with the size of 150 mm × 80 mm × 18 mm (length × width × thickness) were cut randomly from commercial PB products. GB/T 17657-2013 [35], the tests for modulus of rupture and modulus of elasticity of the supplied PBs were repeated five times and their mean values were 17.3 MPa and MPa, respectively. A density of 695.3 kg/m3 and a moisture content of 10.2 ± 2% were documented
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